Apparatus and method for ablating liquefaction of materials

ABSTRACT

Converting thermally meltable materials to a liquefied state is carried out on a lining of pulverulent material. As liquefied material is drained from the surface, additional unmelted material is fed onto the surface to maintain the lining substantially intact.

This is a continuation of application Ser. No. 616,103 filed June 1,1984 now U.S. Pat. No. 4,564,379 which is a continuation-in-part of U.S.patent application Ser. No. 481,970 filed Apr. 4, 1983 now abandoned,which is a continuation-in-part of U.S. patent application Ser. No.288,581, filed July 30, 1981 now U.S. Pat. No. 4,381,934.

BACKGROUND OF THE INVENTION

The present invention relates to converting pulverulent raw materials toa liquefied state as a first step in a melting process. The invention isparticularly applicable to melting glass, including flat glass,container glass, fiber glass, and sodium silicate glass. But theinvention is applicable to other processes that involve thermallyconverting a generally flowable, essentially solid state feed materialto a molten fluid. These other processes may include metallurgicalsmelting type operations and fusing of single or multiple componentceramics, metals, or other materials.

Continuous glass melting processes conventionally entail depositingpulverulent batch materials onto a pool of molten glass maintainedwithin a tank type melting furnace and applying thermal energy until thepulverulent materials are melted into the pool of molten glass.

The conventional tank type glass melting furnace possesses a number ofdeficiencies. A basic deficiency is that several operations, not all ofwhich are compatible with one another, are carried out simultaneouslywithin the same chamber. Thus, the melter chamber of a conventionalfurnace is expected to liquefy the glass batch, to dissolve grains ofthe batch, to homogenize the melt, and to refine the glass by freeing itof gaseous inclusions. Because these various operations are taking placesimultaneously within the melter, and because different components ofthe glass batch possess different melting tempratures, it is notsurprising that inhomogeneities exist from point to point within themelter.

In order to combat these inhomogeneities, a melting tank conventionallycontains a relatively large volume of molten glass so as to providesufficient residence time for currents in the molten glass to effectsome degree of homogenization before the glass is discharged to aforming operation. These recirculating flows in a tank type melterresult in inefficient use of thermal energy and maintaining the largevolume of molten glass itself presents difficulties, including the needto heat such a large chamber and the need to construct and maintain sucha large chamber made of costly and, in some cases, difficult to obtainrefractory materials. Moreover, corrosion of the refractories introducescontaminants into the glass and requires rebuilding of the melter in amatter of a few years. Additionally, it is know that some components ofthe batch such as limestone, tend to melt out earlier than the sand andsink into the melt as globules, whereas higher melting temperaturecomponents, such as silica, tend to form a residual unmelted scum on thesurface of the melt. This segregation of batch components furtheraggravates the problem of inhomogeneities.

Recent findings have indicated that a major rate limiting step of themelting process is the rate at which partly melted liquefied batch runsoff the batch pile to expose underlying portions of the batch to theheat of the furnace. The conventional practice of floating a layer ofbatch on a pool of molten glass is not particularly conducive to aidingthe runoff rate, due in part to the fact that the batch is partiallyimmersed in the molten glass. It has also been found that radiant energyis considerably more effective at inducing runoff than is convectiveheat from the pool of molten glass, but in a conventional melter, onlyone side of the batch is exposed to overhead radiant heat sources.Similarly, conventional overhead radiant heating is inefficient in thatonly a portion of its radiant energy is directed downwardly towards thematerial being melted. Not only is considerable energy waste through thesuperstructure of the furnace, but the resulting thermal degradation ofthe refractory roof components constitutes a major constraint on theoperation of many glass melting furnaces. Furthermore, attempting toheat a relatively deep recirculating mass of glass from above inherentlyproduces thermal inhomogeneities which can carry over into the formingprocess and affect the quality of the glass products being produced.

Many proposals have been made for overcoming some of the problems of theconventional tank type glass melting furnace, but none has foundsignificant acceptance since each proposal has major difficulties in itsimplementation. It has been proposed, for example, that glass batch beliquefied on a ramp-like structure down which the liquid would flow intoa melting tank (e.g., U.S. Pat. Nos. 296,227; 708,309; 2,593,197;4,062,667; and U.S. Pat. No. 4,110,097). The intense heat and severelycorrosive conditions to which such a ramp would be subjected hasrendered such an approach impractical since available materials have anunreasonably short life in such an application. In some cases, it issuggested that such a ramp be cooled in order to extend its life, butcooling would extract a substantial amount of heat from the meltingprocess and would diminish the thermal efficiency of the process. Also,the relatively large area of contact between the ramp and each unitvolume of glass throughput would be a concern with regard to the amountof contaminants that may be picked up by the glass. Furthermore, in theramp approach, a transfer from a radiant source to the melting batchmaterials is in one direction only.

A variation on a ramp type melter is shown in U.S. Pat. No. 2,451,582where glass batch materials are dispersed in a flame and land on aninclined ramp. As in other such arrangements, the ramp in the patentedarrangement would suffer from severe erosion and glass contamination.

The prior art has also suggested melting glass in rotating vessels wherethe melting material would be spread in a thin layer on the interiorsurface of the vessel and would, more or less, surround the heat source(e.g., U.S. Pat. Nos. 1,889,509; 1,889,511; 2,006,947; 2,007,755;4,061,487; and U.S. Pat. No. 4,185,984). As in the ramp proposals, theprior art rotary melters possess a severe materials durability problemand an undesirably large surface contact area per unit volume of glassthroughput. In those embodiments where the rotating vessel is insulated,the severe conditions at the glass contact surface would indicate ashort life for even the most costly refractory materials and asubstantial contamination of the glass throughput. In those embodimentswhere the vessel is cooled on the exterior surface, heat transferthrough the vessel would subtract substantial amounts of thermal energyfrom the melting process, which would adversely affect the efficiency ofthe process. In a rotary melter arrangement shown in U.S. Pat. No.2,834,157 coolers are interposed between the melting material and therefractory vessel in order to preserve the refractories, and it isapparent that great thermal losses would be experienced in such anarrangement. In cyclone type melters, as shown in U.S. Pat. Nos.3,077,094 and 3,510,289, rotary motion is imparted to the glass batchmaterials by gaseous means as the vessel remains stationary, but thecyclone arrangements possess all the disadvantages of the rotary meltersnoted above.

Some prior art processes conserve thermal energy and avoid refractorycontact by melting from the interior of a mass of glass batch outwardly,including U.S. Pat. Nos. 1,082,195; 1,621,446; 3,109,045; 3,151,964;3,328,149; and 3,689,679. Each of these proposals requires the use ofelectric heating and the initial liquefaction of the batch materialsdepends upon convective or conductive heating through the mass ofpreviously melted glass. This is disadvantageous because radiant heatinghas been found to be more effective for the initial liquefaction step.Additionally, only the last two patents listed disclose continuousmelting processes. In a similar arrangement disclosed in U.S. Pat. No.3,637,365, one embodiment is disclosed wherein a combustion heat sourcemay be employed to melt a preformed mass of glass batch from the centeroutwardly, but it, too, is a batchwise process and requires the meltingbe terminated before the mass of glass batch is melted through.

SUMMARY OF THE INVENTION

In the present invention the initial process of liquefying batchmaterial is isolated from the remainder of the melting process and iscarried out in a manner uniquely suited to the needs of the particularstep, thereby permitting the liquefaction step to be carried out withconsiderable economies in energy consumption and equipment size andcost. Central to the invention is the concept of employing glass batchitself as the support surface upon which liquefaction of glass batchtakes place. It has been found that a steady state condition may bemaintained in a liquefaction chamber by distributing fresh batch onto apreviously deposited batch surface at essentially the same rate at whichthe batch is melting, whereby a substantially stable batch layer will bemaintained beneath a transient batch layer, and liquefaction isessentially confined to the transient layer. Thus, the partially meltedbatch of the transient zone runs off the surface while contactingsubstantially only a batch surface, thus avoiding contaminating contactwith refractories. Because glass batch is a good heat insulator,providing the stable batch layer with sufficient thickness protects anyunderlying support structure from thermal deterioration. Because theexterior of a furnace can thus be protected thermally, as well as fromcontact with corrosive molten materials, the materials requirements canbe greatly relaxed, even permitting the use of mild steel as a furnacehousing. The economies thus achieved in furnace construction can besubstantial. Furthermore, because the furnace housing is protected bythe insulating effect of the stable batch layer, no cooling of thesupport surface is required, thereby avoiding extraction of useful heatfrom the melting process.

The stable batch surface upon which liquefaction is carried out may besloped in order to expedite runoff of the liquefied batch. The slope maybe the natural angle of repose of the glass batch, or the angle may beincreased by providing a preformed batch layer or by centrifugal forcein a rotating furnace vessel. The runoff surface is preferably free fromobstacles to flow so as to permit free drainage of the liquid out of theliquefaction zone into a subsequent zone where additional meltingoperations may be performed on the liquid. The liquid leaving theliquefaction zone is by no means a completely melted glass, but is afoamy, opaque fluid including unmelted sand grains and the like.However, it has been found that the additional energy required tocomplete the dissolution and refining of this runoff liquid constitutesa very small portion of the total energy required to melt glass in aconventional tank type melting operation. Thus, the relatively efficientliquefaction process of the present invention replaces a major energyconsuming portion of the conventional melting process. Additionally, ithas been found that the runoff liquid is surprisingly uniform intemperature and composition, and therefore each increment of the liquidhas essentially identical needs for subsequent processing. Thisminimizes the need for subsequent homogenization and permits preciselytailoring the subsequent process steps to the specific needs forconverting the runoff liquid to molten glass finished to the degreerequired for the product being produced.

Liquefaction of the batch is brought on by melting of the lowesttemperature-melting components of the batch. Thus, the liquid begins toflow out of the liquefaction zone at a temperature considerably belowthe temperature required for complete melting of glass, therebyadvantageously limiting the function of the liquefaction zone to theunit operation of liquefying the batch. Essentially no increment of theliquefied batch is heated in the zone to a temperature substantiallyabove that corresponding to the onset of flowability. As a result, thefluid leaves the zone at a relatively low, uniform temperature, and thecavity temperature within the liquefaction zone also remains relativelylow. This has advantages for the construction of the liquefactionchamber and for reducing heat losses therefrom. The ability toaccomplish a major step in the melting process without wastefullyoverheating some increments of the melt also has positive implicationsfor energy conservation and for suppressing volatilization of somerelatively volatile components that are sometimes included in the batch(e.g., sulfur and selenium).

In preferred embodiments of the invention, the thermal efficiency of theliquefaction process is further increased by providing a stable batchlayer that substantially encircles a radiant heat source. Typically, thebatch surface may constitute a surface of revolution (e.g., a cylinderor frustum). In this manner, radiant energy being emitted by the sourcewill impinge directly upon batch being melted over a wide range ofangles. Such an arrangement also permits an efficient use of hightemperature heat sources, such as oxygen enriched flames, since much ofthe enhanced heat flux from such a source will productively impinge uponthe surrounding batch surface. In the most preferred embodiments, theconcept of encircling the heat source is combined with rotating thebatch surface so as to increase the angle of repose.

The present invention may also be employed to improve the emissions of aglass melting furnace. Sulfates included in many glass batch formulasare known to contribute significantly to desirable emissions from glassfurnaces. A major purpose for including sulfates in a glass batch is toaid the initial liquefaction process in a conventional tank melter. Butsince the present invention is specifically adapted to liquefying glassbatch, it has been found that efficient liquefaction can be achievedwithout the presence of sulfates in the batch. Thus, the presentinvention permits omitting sulfates from the batch, thereby eliminatingthe resultant emissions.

It has also been found that wetting the batch with water as isconventionally done in order to control dusting is not necessary withthe present invention. Since vaporizing the water consumes energy in amelter, elimination of the water improves the energy efficiency. Evenmore significantly, the ability to use dry batch means that preheatedbatch may be fed to the process. If the batch is preheated by heatrecovery from the exhaust gas stream, substantial energy savings can beattained. It is an advantage of the present invention that the processcan accommodate preheated, dry, particulate batch, whereas prior artproposals to recover waste heat by preheating batch have usually beentied to the use of agglomerated batch. It has been found generally thatthe cost of agglomerating batch on a commercial scale virtually negatesthe potential energy savings.

Liquefying batch in accordance with the present invention is carried outin a relatively compact vessel rather than the conventional tank typemelter which contains a pool of molten glass. Reducing the size savessubstantial construction costs. Also, by eliminating the need for alarge residual pool of glass, product change-overs are facilitated bythe present invention.

The invention will be more fully understood in view of the detaileddescription of several specific embodiments which follows.

THE DRAWINGS

FIG. 1 is a vertical cross-section through a first embodiment of thepresent invention featuring an elevated batch pile surrounded by heatsources.

FIG. 2 is a vertical cross-section through a second embodiment of thepresent invention featuring a sloped batch surface.

FIG. 3 is a vertical cross-section of a third embodiment of the presentinvention featuring a compacted, sharply sloping batch surface.

FIG. 4 is a vertical cross-section through a fourth embodiment of thepresent invention featuring a frusto-conical batch surface encircling aheat source.

FIG. 5 is a vertical cross-section of a fifth embodiment of the presentinvention wherein an inclined rotary kiln provides a cylindrical batchsurface.

FIG. 6 is a vertical cross-section of a preferred embodiment of thepresent invention wherein a drum rotating about a vertical axis ofrotation provides a batch surface which is a paraboloid surface ofrotation about a heat source.

FIG. 7 is a vertical cross-section of a schematic representation of acombustion melting furnace adapted to cooperate with the batch liquifierof the embodiment of FIG. 6.

FIG. 8 is a vertical cross-section of a schematic representation of anelectric melting furnace adapted to cooperate with the batch liquefierof the embodiment of FIG. 6.

FIG. 9 is a vertical cross-section of a preferred variation on the typeof embodiment shown in FIG. 6.

DETAILED DESCRIPTION OF THE EMBODIMENTS

A number of embodiments incorporating the principles of the presentinvention will be described, but it should be understod that thepractice of the invention is not limited to the specific structuresdisclosed. Also, since the invention relates to the initial step ofliquefying glass batch, the descriptions of the embodiments will belimited to what would be only the initial portion of most glass meltingoperations. It should be understood that where the product requires, theinventive liquefaction step may be employed in combination withconventional means for further melting, refining, conditioning andforming the glass.

FIG. 1 represents a simplified version of the present invention whereina liquefaction chamber is defined by a refractory brick enclosure 10. Arefractory pedestal 11 rises above (or slightly below) the level of apool of molten glass 12 within the enclosure. A mound of glass batch 13supported on the pedestal 11 may be either a loose pile of batch or amolded, preshaped mass of batch in the form of a hemisphere, cone,pyramid, tetrahedron or the like. The contour of the batch mound 13 maybe maintained substantially stable by continuously replenishing thebatch by means of a falling stream of batch 14 fed from a screw feeder15 or the like through an opening 16 in the roof of the enclosure 10.Heat for melting is provided by radiant energy sources 17 which may becombustion burners as shown in FIG. 1 or any other radiant source suchas electric arc heaters. In this embodiment, the radiant energy sourcesare preferably arranged to provide substantially uniform heat to allsides of the batch mound 13. As the batch liquefies, a fluid layer 18runs down the surfaces of the batch mound 13 and falls into the pool ofglass 12. By controlling the relative amout of heat input and batchbeing fed in stream 14, a steady state condition may be maintainedwhereby the batch mound 13 remains substantially stable and theliquefaction is substantially confined to the transient layer 18 and thenewly introduced batch stream 14. The partially melted runoff in pool 12may be passed from the liquefaction chamber to a subsequent chamber 19for completing the melting of any residual particles and for otherwiseprocessing the glass by methods well known in the art.

In the arrangement shown in FIG. 2, a liquefaction chamber defined by arefractory enclosure 20 includes a shelf portion 21 on which rests abatch mound 22. The batch mound presents a surface sloping downwardly insubstantially one direction and facing a radiant heat source such as aburner 23. As shown in the drawing, the batch mound may assume thenatural angle of repose of the pulverulent batch material. A layer ofliquefied batch 24 runs off the batch mound 22 and over a refractory lip25 at a bottom exit opening 26 through which the liquid passes from theliquefaction chamber to subsequent processing stations, which may entaila pool of molten liquid 27 in a subsequent chamber 28. Since the batchitself acts as an insulator, the refractory material from which most ofthe shelf portion 21 of the enclosure is fabricated need not provideexceptional thermal durability, thereby permitting use of economicmaterials. Only at the small lip area 25, where the batch mound isrelatively thin and where the molten material contacts the supportrefractories, is it advisable to provide a durable refractory materialsuitable for molten glass contact such as fused quartz or fused castalumina. Beneath a layer of batch of about 3 centimeters or more, thethermal durability requirements for the underlying refractory arenegligible. As shown in FIG. 2, exhaust combustion gases may escape fromthe liquefaction chamber by way of a flue 29. Alternatively, thecombustion gases may pass through the exit opening 26 and into thedownstream chamber 28 so as to expend more of its thermal energy there.In order to maintain a substantially fixed interface between the stablebatch mound 22 and the transient liquid layer 24, batch is continuouslyfed to the melting area. Batch may be distributed over the melting areaby any suitable mechanical means or, as shown, the incoming batch may bedispersed by the combustion flame. Batch may be fed by way of a screwconveyor 30 to a ceramic tube 31 extending into the interior of theliquefaction chamber and opening in the vicinity of the burner 23.

FIG. 3 depicts a variation on the embodiment of FIG. 2. A refractoryenclosure 35 defines the liquefaction chamber wherein the batch layer 36is supported on a steeply sloped surface 37 rather than on a horizontalshelf. The batch layer 36 is provided with a slope sharper than theangle of repose of loose batch by preforming the batch layer into arigid slab. Glass batch may be preformed by molding batch which has beenwetted with water. The batch layer 36 may be retained in place by arefractory lip piece 41 which is preferably a material suitable formolten glass contact of the type described above. An example of aradiant heat source illustrated in FIG. 3 is an electric arc produced bya pair of electrodes 38 and 39 extending into the liquefaction chamber.It should be understood that the liquefaction chamber of either FIG. 2or FIG. 3 may include a plurality of radiant heat sources so as topermit the melting area to be extended. Loose batch is deposited ontothe batch layer 36, becomes liquefied and runs off as a liquid layer 40which passes through a bottom exit opening 42 from the liquefactionchamber and may be gathered in a molten pool 43 within a chamber 44 forsubsequent treatment. The loose batch may be fed by means of a screwfeeder 45 to an opening 46 through the top of the liquefaction chamber.The relatively steep slope of the melting surface in the FIG. 3embodiment may be an advantage for accelerating the runoff of theliquefied batch as well as for simplifying distribution of incomingbatch over the melting area. In some cases it may be desirable for theslope to be vertical or nearly vertical.

The embodiment of FIG. 4 has a preferred feature wherein the batch layerencircles the radiant heat source. Such an arrangement advantageouslyresults in a greater portion of the radiant energy productivelyimpinging upon the batch material and permits greater utilization of theinsulative effect of the batch layer. Because the heat source isencircled by the insulating batch layer, refractory materials need notbe employed for the sidewalls of the housing in the FIG. 4 embodiment.Thus, the housing may comprise a steel vessel 50 which may be providedwith a frustoconical shape as illustrated, which may be generallyparallel to the interior surface of the batch layer. However, the slopedsurface of the batch layer need not correspond to the shape of thehousing, and the housing may take any form such as a cylindrical or boxshape. A cover 51 of ceramic refractory material may be provided toenclose the upper end of the liquefaction vessel. Batch 52 may be fedfrom a ring-type vibratory feeder 53 through an annular opening 54 inthe cover 51 so that the batch enters the upper end of the vesselsubstantially evenly distributed around its upper periphery. A sloping,stable batch layer 55 lines the sides of the interior of theliquefaction vessel and may be comprised of loose batch or a preformed,molded lining. As shown in the drawing, the surface of the batch layerfacing the heat source is preferably a surface of rotation, in this casea frusto-conical shape parallel to the shape of the housing 50.Paraboloid and cylindrical surfaces may also be employed. However, itshould be understood that while surfaces of revolution are preferred forthe shape of the batch layer for the sake of receiving uniform heat froma central heat source, other non-revolutionary shapes may be employed,such as inverted pyramidal or tetrahedral shapes. It may be also notedthat the batch layer need not be of uniform thickness as long as theminimum thickness is sufficient to provide the desired degree ofinsulation. Because of the excellent insulating properties of glassbatch, a stable batch layer whose minimum thickness is on the order ofabout 3 centimeters to 5 centimeters, has been found more than adequateto protect a steel housing from undue thermal deterioration. Arefractory ceramic bushing 56 at the bottom of the liquefaction chamberhelps to retain the batch layer 55 in place, and a central opening 57 inthe bushing defines an exit opening from the liquefaction chamber. Asource of radiant energy, such as a burner 58 provides heat within theliquefaction zone for melting the batch being fed into the chamber whichforms the transient layer 59. The transient layer 59 becomes fluid andflows downwardly through the exit opening 57. The liquefied batch may becaptured in a pool 60 contained by a chamber 61 for subsequentprocessing. Combustion gases from the liquefaction zone may also passthrough the opening 57, whereupon they may be discharged from thechamber 61 through a flue 62. Alternatively, an exhaust opening may beprovided through the cover 51. FIG. 4 shows a single heat source 58centrally located on the axis of the liquefaction zone but it should beunderstood that a plurality of heat sources could be provided withoblique orientations.

Referring now to FIG. 5, there is shown an embodiment featuring a rotaryliquefaction zone. High thermal efficiency is provided by encircling theheat source with the batch material being melted, and the transientbatch layer being melted is distributed within the vessel by means ofits rotation. The rotating vessel comprises an inclined steel cylinder65 which may be rotated by way of a motor 66. Loose glass batch may befed to the upper open end of the cylinder by means of a screw feeder 67.Before the vessel is heated, an insulating layer of batch 68 is built upwithin the vessel. During operating, the rate of feeding the batch andthe rate of heating are balanced against one another so that the layer68 remains stable and serves as the surface upon which newly fed batchis melted and runs toward the lower end of the cylinder. A radiant heatsource such as a combustion burner 69 may be oriented along the axis ofthe cylinder from either end of the cylinder. As shown in FIG. 5, theburner 69 is mounted in a refractory housing 70 which closes the lowerend of the cylinder 65. The combustion gases pass axially through thecylinder and escape through the upper end into an exhaust box 71 whichencompasses the upper end of the cylinder. Exhaust gases may be passedfrom the box 71 to a stack 72. The lower end of the rotating cylindermay be provided with a refractory ceramic bushing 73 suitable for moltenglass contact. A gap 74 between the burner housing 70 and the bottominside edge of the cylinder is provided for escape of the liquefiedbatch 75 which may fall into a collecting pool 76 contained by a chamber77 where the molten material may be subjected to subsequent processing.The angle of incline of the rotating cylinder will be determined by therate at which it is desired for the liquefied batch to run out of thecylinder. The cylinder should rotate at a speed at which loose batch isheld against the inside walls by centrifugal force. The minimum speedwill depend upon the effective diameter of the cylinder. The followingare calculated estimates:

    ______________________________________                                        Diameter    Revolutions per Minute                                            ______________________________________                                        0.5 Meters  60                                                                1.0 Meters  43                                                                2.0 Meters  37                                                                ______________________________________                                    

The preferred embodinent is shown in FIG. 6 and is characterized by aliquefaction chamber rotating about the vertical axis, with glass batchencircling a central heat source. The rotary melter 80 of thisembodiment includes a housing comprising a steel cylinder 81 and a steelfloor 82. The housing is provided with vertical support by a pluralityof rollers 83 which are affixed to a frame 84. A plurality of siderollers 85 maintain alignment of the housing. Rotation of the housingmay be provided, for example, by driving one of the roller 83 or 85 bymotor means (not shown). A central opening in the floor 82 is providedwith a refractory ceramic bushing 86 suitable for molten glass contactand having a central opening 87. Any suitable structure may be providedfor supporting frame 84 but for purposes to be described hereinafter, itis preferred to make the entire liquefaction structure 80 relativelyportable. Therefore, overhead hoist means may engage attachment means 88affixed to upper portions of the frame 84. The upper end of the vesselmay be closed by a refractory lid 90 which may be stationary andsupported by the frame. The lid 90 is provided with a central bore 91through which a burner 92 or other radiant heating means may beinserted. Alternatively, a plurality of heat sources may be employed.The lid is also provided with a feed opening 93 whereby batch may be fedfrom a screw feeder 94 or the like to the interior of the vessel. Beforethe vessel is heated, a stable layer of batch 95 is provided in thevessel by feeding loose batch while the housing is rotated. The loosebatch assumes a generally paraboloid contour as shown in FIG. 6. Theshape assumed by loose, dry batch is related to the speed of rotation asfollows:

    H=μR+(2π.sup.2 ω.sup.2 R.sup.2)/g

Where:

H=the elevation of a point on the batch surface in the directionparallel to the axis of rotation;

R=the radial distance of that point from the axis of rotation;

μ=a friction factor;

ω=angular velocity; and

g=the acceleration of gravity.

The friction factor may be taken as the tangent of the angle of repose,which for dry glass batch is typically about 35°. The above equation maybe employed to select suitable dimensions for the rotary vessel at aselected speed of rotation or, conversely, for determining a suitablespeed of rotation for a given vessel. The relationship shows thatsteeper slopes, which are generally preferred, require faster rotationalspeeds, and that at zero velocity, the slope is determined solely by theangle of repose as in the FIG. 4 embodiment (assuming no preforming ofthe batch layer).

During heating, continuous feeding of batch to the vessel of FIG. 6results in a falling stream of batch 96 that becomes distributed overthe surface of the stable batch layer, and by the action of the heatbecomes liquefied in a transient layer 97 that runs to the bottom of thevessel and passes through opening 87. The liquefied batch falls asglobules 98 from the exit opening and may be collected in a pool 99within a vessel 100 for further processing. Exhaust gases from thecombustion within the liquefaction vessel may also pass through theopening 87 and may be exhausted through a flue 101. Alternatively, anexhaust opening may be provided through the lid 90.

In FIGS. 7 and 8, there are depicted combinations of the rotary melter80 of the FIG. 6 embodiments combined with conventional means forcompleting the melting of the liquefied batch. In order to melt residualsand grains and to refine the liquefied batch emanating from the rotarymelter 80, an overhead fired furnace 110 of conventional constructionmay be provided as shown in FIG. 7. The furnace contains a pool of themelt 111 and may be provided with one or more side ports 112 or an endport, as are well known in the art, from which flames may be directedabove the melt for providing heat thereto. The furnace may include aconventional inlet extension portion 113, but rather than feeding batchat such a location, the output from one or more batch liquefiers may befed to the furnace through an opening 114. Melted and refined glass maypass from the furnace to a forming operation by way of a conditioner orforehearth 115. The function of the furnace 110 is priaarily to raisethe temperature of the melt and to provide sufficient residence time forany residual sand grains to dissolve and for gaseous inclusions toevolve from the melt. These functions represent a minor portion of thosecarried out in a conventional melting furnace, and therefore the furnace110 may be only a fraction of the size of a conventional furnace havingthe same throughput. In other words, it is estimated that the batchliquefaction means of the present invention may replace one-half totwo-thirds of a conventional flat glass melting furnace withcommensurate savings in construction costs and with more efficientenergy usage. A single liquefaction vessel may be used to provideliquefied batch to the furnace of a large scale, commercial glassmakingoperation, but it is generally more economical to provide a plurality ofsmaller units. Thus, to supply a throughput on the order of severalhundred tons per day, it may be preferred to employ about three or fourliquefaction units. It is preferred that each liquefaction unit be madeportable so that a unit in need of maintenance may be removed and areserve unit inserted in its place, thereby minimizing disruption of theglassmaking operation. The use of a plurality of liquefaction units alsoprovides an economical means for varying the throughput of theglassmaking operation by increasing or decreasing the number of units inoperation.

FIG. 8 illustrates another arrangement for completing the melting andrefining of the output from one or more rotary liquefaction units 80,employing electric heat rather than overhead combustion firing. Theelectric melter 120 may be comprised of a refractory vessel 121 intowhich are inserted a plurality of electrodes 122 by which thermal energyis imparted to the melt by means of Joule resistance heating. Theliquefied batch from a liquefaction unit or units may enter the electricmelter through an opening 123. Following elevation of the melttemperature by the electric heating, a stream of the melt may passthrough a submerged throat 124 to a refining zone 125 where gaseousinclusions are permitted to escape from the melt. It should beunderstood that in the arrangements shown in FIGS. 7 and 8, the rotaryliquefaction unit 80 is illustrated as the preferred embodiment, butthat the other liquefaction units disclosed herein may be used in placethereof.

In a typical glass batch formula consisting primarily of sand, soda ashand limestone, the soda ash begins to melt first, followed by thelimestone, and finally the sand. Physical melting is accompanied bychemical interactions, in particular, the molten alkalis attack the sandgrains to effect their dissolution at a temperature below the meltingpoint of silica. At some intermediate point in this process, the liquidphase of the heterogeneous mixture of reacting and melting materialsbegins to predominate and the material becomes flowable as a fluid. Thetemperature at which the batch becomes flowable will depend upon theparticular batch formula, especially the amount and melting temperatureof the lowest melting temperature ingredients. The most common lowtemperature melting ingredient is soda ash, which melts at 1564° F.(851° C.). Theoretically, a batch having a sufficient amount of soda ashmay become liquefied at the soda ash melting temperature, but experiencewith commercial batch formulas indicates that the temperature issomewhat higher--2000° F. (1090° C.) to 2100° F. (1150° C.) for atypical flat glass batch. This may be explained by the fact that batchmelting is a complex series of interactions among the variousingredients, whereby the physical properties of the individualingredients are not exhibited. It may also be that insufficient soda ashis present when melted to entrain by itself the remainder of theunmelted materials. Moreover, even though the present inventioneliminates much of the overheating of conventional melters, the runofftemperatures observed with the present invention may not truly representthe initiation of liquefaction, but may include a small amount ofheating after liquefaction. Other low temperature melting ingredientssometimes employed in glass batches, such as caustic soda and boricacid, have even lower melting temperatures than soda ash and may behavedifferently as runoff initiators. On the other hand, some types of glassother than flat glass require higher temperatures to melt. It ispreferred to use the present invention with batch formulas that liquefybelow 3000° F. (1650° C.). For many types of glasses made on a largescale commercially, the present invention would be expected to operatesatisfactorily with liquefied batch draining from the liquefactionchamber at about 1600° F. (870° C.) to 2300° F. (1260° C.).

In the present invention, the liquefied batch drains from theliquefaction zone as soon as it reaches the fluid state, and thereforethe fluid draining from the liquefaction zone has a nearly uniformtemperature close to the liquefying temperature of the particular batchformula, typically about 2100° F. (1150° C.) in the case of conventionalflat glass. Because heat is transported out of the liquefaction zone atthe liquefying temperature, which is considerably lower than thetemperatures attained in a conventional glass melter, the temperature ofthe liquefaction vessel may be maintained relatively low regardless ofthe temperature of the heat source. As a result, materials requirementsmay be reduced relative to a conventional melter, and use of hightemperature heat sources is made possible. The greater heat fluxafforded by high temperature heat sources advantageously increases therate of throughput. An example of a high temperature heat source is acombustion burner supplied with oxygen as a partial or total replacementfor combustion air. The use of oxygen is also advantageous in thepresent invention for the sake of reducing the volume of combustiongases, thereby decreasing any tendency of the find batch materials tobecome entrained in the exhaust gas stream. This is particularlysignificant in the preferred practice of feeding the batch dry to theliquefaction vessel as opposed to the conventional practice of wettingthe batch with water to inhibit dusting. Furthermore, the use of oxygeninstead of air is believed to reduce the potentiality for creatingnitrogen containing bubbles in the glass.

An example of a batch formula employed in the commercial manufacture offlat glass is the following:

    ______________________________________                                        Sand              1000 parts by weight                                        Soda ash           313.5                                                      Limestone          84                                                         Dolomite           242                                                        Rouge              0.75                                                       ______________________________________                                    

The above batch formula yields approximately the following glass:

    ______________________________________                                        SiO.sub.2        73.10%  by weight                                            Na.sub.2 O       13.75%                                                       CaO              8.85%                                                        MgO              3.85%                                                        Al.sub.2 O.sub.3 0.10%                                                        Fe.sub.2 O.sub.3 0.10%                                                        ______________________________________                                    

The liquefied batch running out of the liquefaction zone of the presentinvention, when using the batch formula set forth above, ispredominantly liquid (weight basis) and includes about 15% by weight orless of crystalling silica (i.e., undissolved sand grains). The liquidphase is predominantly sodium disilicate and includes almost the entiresoda ash portion of the batch and most of the limestone and dolomite.The fluid, however, is quite foamy, having a density typically on theorder of about 1.9 grams per cubic centimeter, as opposed to a densityof about 2.5 grams per cubic centimeter for molten glass.

Although additional energy must be imparted to the liquid to convert itto a completely melted glass, it is estimated that a major portion ofthe overall energy consumption is spent in the batch liquefactionprocess, and that that portion of the process is carried outsubstantially more efficiently by the liquefaction methods of thepresent invention compared to a conventional tank-type melter. Atheoretically derived value for the total energy required to completelymelt glass is 2.5 million BTU's per ton (0.7 million kcal/metric ton) ofglass produced. In order to complete the melting of the material leavingthe liquefaction zone of the present invention, it is calculated thattheoretically 0.36 million BTU's per ton (0.1 million kcal/metric ton)would be required, or about 14% of the total theoretical energyrequirement. In a conventional overhead fired tank melting furnaceoperating at state-of-the-art efficiency, total energy consumption hasbeen found to be typically about 6.25 million BTU's per ton (1.75million kcal/metric ton) of glass produced. The liquefaction process ofthe present invention, on the other hand, has been found to consume,typically, about 4.5 million BTU's per ton (1.26 million kcal/metricton). Accordingly, it can be seen that the liquefaction step performedin accordance with the present invention accomplishes about 86% of themelting while consuming about 72% of the energy required by aconventional melter. The total energy efficiency of the presentinvention will depend upon the efficiency of the particular processemployed to complete the melting of the liquefied batch, but if theefficiency of the subsequent stage is no better than the efficiency of aconventional tank-type melter, it can be estimated that the overallenergy consumption for melting glass in accordance with the presentinvention would be about 5.4 million BTU's per ton (1.5 millionkcal/metric ton), or about 86% of the anount of energy used in theconventional melting process. In fact, it is contemplated that theenergy efficiency of subsequent processing steps employed in conjunctionwith the batch liquefaction of the present invention would be betterthan that of the conventional melting process, since conditions may beprovided that are particularly adapted to the specific tasks of meltingresidual sand grains and removing gaseous inclusions from the melt.Furthermore, the energy consumption figures employed above for theconventional melting process include heat recovery from the exhaustgases, whereas the figures for the liquefaction process of the presentinvention do not. Therefore, employing conventional heat recovery meanswith the process of the present invention may be expected to lower itsenergy requirements further.

A pilot scale trial of the embodiment of FIG. 6 employed a steelcylindrical drum 18 inches (46 centimeters) high and having an insidediameter of 25.25 inches (64 centimeters). Optimum rotation of the drumwas found to be in the range of 42 to 48 revolutions per minute in orderto form a stable layer of loose batch covering the inside wall of thedrum. The bottom exit opening has an 8 inch (20 centimeter) diameter.The burner was fired with natural gas and oxygen in stoichiometric ratioand expended 4.3 million BTU's per ton (1.2 million kcal/metric ton) ofliquefied batch produced. The maximum production rate attained was 2.8tons per day of liquefied batch.

FIG. 9 shows an improved version of the vertical axis rotating drumembodiment of FIG. 6. In the FIG. 9 version a drum 130 has stepped sidesso as to decrease the amount of mass being rotated. The drum could, ofcourse, be a conical shape as in FIG. 4, but the stepped construction ispreferred for ease of fabrication. The drum 130 is supported on acircular frame 131 which is, in turn, mounted for rotation about agenerally vertical axis corresponding to the center line of the drum ona plurality of support rollers 132 and aligning rollers 133. A bottomsection 135 houses an outlet assembly which may be detached from theremainder of the drum. The housing 135 may be lined with an annulus ofrefractory material 136 such as castable refractory cement in which isseated a ring-like bushing 137 of erosion resistant refractory. Thebushing 137 may be comprised of a plurality of cut pieces of ceramic. Anopen center 138 in the bushing 137 comprises the outlet opening from theliquefaction chamber. An upwardly domed refractory lid 140 is providedwith stationary support by way of a circular frame member 141. The lidincludes an opening 142 for insertion of a burner 14. In this embodinentthe exhaust gases escape upwardly through an opening 144 through the lid140 and into an exhaust duct 145. The opening 144 may also be utilizedfor feeding the raw materials to the liquefaction chamber and in theFIG. 9 embodiment, a feed chute 150 is provided for this purpose. Thebottom end of the feed chute 150 may be provided with a movable baffle151 for the purpose of controlling the location at which the rawmaterials are deposited into the liquefaction chamber. Upper and lowerwater seals 152 and 153 respectively, may be provided to isolate theinterior of the liquefaction chamber from the exterior ambientconditions and to trap any dust or vapors that may escape from thevessel. As in the previous embodiments, a stable layer of unmeltedmaterial 154 is maintained within the liquefaction chamber and on thisstable layer a transient layer 155 melts and flows downwardly throughthe bushing outlet 138. The liquefied material 156 then falls into acollection vessel 157.

Although the description of the invention heretofore has relatedspecifically to liquefying glass batch, it should be apparent that theprinciples of the invention may apply to other materials as well,particularly materials that are initially in a flowable solid form(i.e., granular or pulverulent) and are thermally meltable to a flowablefluid state. Flowability is a desirable characteristic of the feedmaterial for the sake of distributing the material onto the meltingsurface within the liquefaction chamber. Typically the feed will chieflycomprise subdivided solids, but may include a liquid portion. It is alsowithin the scope of the invention to feed a plurality of streams intothe liquefaction chamber, some of which may be liquids. In general, thecombined feed for use in the present invention may be characterized ashaving a greater frictional resistance to flow down the surface of thestable layer than does the liquefied material. Thus, the materialinitially remains exposed to the heat until it becomes liquefied,whereupon it flows out of the liquefaction zone. Combinations ofproperties analogous to those in the liquefaction of glass batch may befound in the fusing of ceramic materials and the like and inmetallurgical smelting type operations.

Whatever material is being processed, the vessel of the embodiment ofFIGS. 4, 5 or 6 is insulated from the interior heat by a substantiallystable layer of material maintained on the interior of the vessel. It isdesirable for the thermal conductivity of the material employed as thestable layer to be relatively low so that practical thicknesses of thelayer may be employed while avoiding the need for wasteful forcedcooling of the vessel exterior. In general, granular or pulverulentmineral source raw materials provide good thermal insulation, but insome cases it may be possible to use an intermediate or product of themelting process as a non-contaminating stable layer. For example, in aglassmaking process, pulverized cullet (scrap glass) could constitutethe stable layer, although a thicker layer would be required due to thehigher thermal conductivity of glass as compared to glass batch. Inmetallurgical processes, on the other hand, using a metallic product asthe stable layer would entail unduly large thicknesses to providethermal protection to the vessel, but some ore materials may besatisfactory as insulating layers.

In commercial glassmaking operations, glass batches often includesubstantial amounts of cullet, or scrap glass. The present invention canaccommodate conventional cullet-containing batches, and could be used tomelt cullet alone. The cullet may be mixed with the other batchconstituents prior to feeding, or the cullet may be fed into theliquefaction zone as a separate stream.

An advantage of the present invention is that it can accommodate dry,loose batch materials, thereby avoiding the necessity to agglomerate thebatch materials if it is desired to preheat the batch materials. Itshould be apparent, however, that the use of agglomerated batch is notprecluded by the present invention. Thus the feed to the liquefactionvessel may comprise pellets, biquettes, granules, pre-melted marbles, orother agglomerated forms.

A feature of the invention is that melting takes place in a transientlayer that is supported by and flows on a stable layer. It should beunderstood that the terms "transient" and "stable" are relative, andthat a distinct physical demarcation between the transient and stablelayers may not always be identifiable. The use of the terms "transient"and "stable" is not intended to preclude the possibility that minorfluctuation of the interface therebetween may occur. The basicdistinction is that the region that is described as the transient layeris characterized by melting and flowing, whereas the region termed thestable layer, in at least its major portion, does not participate in themelting and flowing of the throughput stream. Although the transientlayer is said to be "on" the stable layer, one might theoreticallydefine an intermediate layer therebetween, and it should be understoodthat that possibility is intended to be included. For example, it wouldbe within the ambit of the invention as expressed to feed a plurality ofconstituents in a stratified manner onto the melting surface.

In the preferred embodiments, the stable layer is preferably ofessentially the same composition as the material being processed.However, it should be understood that precursor or derivative materialswould be considered "essentially the same composition" in this context.In other words, the stable layer could be the raw material, the productmaterial, an intermediate, or a different form or mixture thereof, aslong as it melts or reacts to form a substance that does not introducesignificant amounts of foreign constituents into the throughput stream.It should also be evident that this compositional requirement of thestable layer need apply only to surface portions that actually contactthe throughput stream and to portions just under the surface that mayoccasionally erode into the throughput stream. Therefore, an equivalentarrangement might employ a different material in portions of the stablelayer below the level at which erosion is likely to occur. Since thissubsurface portion serves primarily as insulation to protect the vessel,it could be composed of a material selected for its thermal insulatingproperties (e.g., sand or ceramic particles), although it should besufficiently compatible compositionally to not contaminate the surfacelayer at the temperatures involved.

Of course, a compositional variation of the throughput material causedby contact with the lining which is within the limits of toleration forthe quality requirements of the particular product being made would notbe considered contaminating. The compositional control requirements forbottle glass or fiber glass are not as high as for flat glass or opticalglass, and therefore could tolerate greater compositional differencesbetween the throughput material and the lining without being consideredcontaminating. For example, boron (usually express as B₂ O₃) is oftenincluded in fiber glass compositions and is useful in the meltingprocess, but stringent control of the B₂ O₃ content of the final productis not always necessary. Therefore, liquefying fiber glass batchcontaining B₂ O₃ would be consistent with the principles of the presentinvention.

A common fiber glass composition is the "E glass" type, having thefollowing composition (in weight percent):

    ______________________________________                                               SiO.sub.2                                                                            52-55%                                                                 Al.sub.2 O.sub.3                                                                    14-15                                                                   B.sub.2 O.sub.3                                                                      7-10                                                                   MgO   0-5                                                                     CaO   17-22                                                                   Na.sub.2 O                                                                          0.3-0.5                                                                 K.sub.2 O                                                                           0.1-0.9                                                                 Fe.sub.2 O.sub.3                                                                      0-0.4                                                                 F.sub.2                                                                               0-0.6                                                          ______________________________________                                    

The batch source of boron is usually colemnite or boric acid.

Also, it should be apparent that a compositional difference between thelining and the material being liquefied that consists of a componentthat is volatilized or otherwise substantially eliminated from theliquefied material by the melting process or other subsequent treatmentswould not be considered contaminating. For example, it is well known toinclude in glass batch formulas refining aids such as sulfur, fluorine,antimony, or arsenic. The presence of these refining aids during meltingis considered useful, but they are sometimes largely volatilized andtheir concentration, if any, in the final glass product is usually notcritical. Therefore, in many cases, it would be acceptable for thelining to be free of such a refining aid that may be present in thethroughput material. In another example, when the liquefaction processof the present invention is employed as part of an ore smeltingoperation, the liquefaction step would be followed by a purificationprocess in which the metal is separated from the slag. In such a case,erosion of minor amounts of a lining of a substantially differentcomposition (e.g., sand) into the liquefied ore would not beobjectionable since the liquefied ore would be subsequently purified. Ina similar example, silica is produced by melting a sodium silicateglass, dissolving the glass in water, and then precipitating silica. Insuch a process the initial melting step may be performed by the processof the present invention with a pulverulent lining (e.g., sand) somewhatdifferent in composition from that of the batch feed material, sinceentrained, unmelted particles of the lining can be settled from thesolution after the dissolving step. In another well-known process,certain glass compositions are phase separated and leached to producehigh silica products. When liquefying such a glass by the process of thepresent invention, any constituent that is contributed by the lining tothe phase that becomes leached would, of course, not be consideredcontaminating.

In those situations where contamination of the throughput material isnot of primary concern, the present invention offers an advantage in itsuse of a pulverulent lining in the liquefaction vessel. Whereas a solidrefractory lining is subject to cracking, spalling, and displacement, apulverulent lining is not. Installing a solid refractory lining entailscareful, time-consuming shaping and placement of a plurality of pieces,but the pulverulent lining of the present invention is formed simply bypouring the material into the vessel. In time, a refractory lining willerode and require replacement, necessitating a complete shut-down of theprocess for re-lining. In the present invention, on the other hand, thepulverulent lining repairs itself during use by means of batch material,or if re-lining with a material other than the batch material isdesired, by a brief interruption of the continuity of the process whilea charge of the lining material is fed to the vessel. The pulverulentlining also provides more flexibility in a periodically operated processin that it does not require the slow heat-up and cool-down periodsentailed by a solid refractory lining.

Other modifications and variations as would be obvious to those of skillin the art may be resorted to without departing from the scope of theinvention as defined by the claims which follow.

We claim:
 1. A method of melting glassy materials or the likecomprising: rendering batch materials to a partially melted, flowablestate on a sloped layer of pulverulent material encircling a heatedcavity; permiting the partially melted material to flow substantiallyfreely from the cavity; gathering the drained material in a pool; andheating the material in the pool to further melt the material.
 2. themethod of claim 1 wherein batch material is partially melted in aplurality of cavities from which partially melted material is passed tothe pool.
 3. The method of claim 1 wherein the material draining fromthe cavity includes unmelted particles, and melting of the particles issubstantially completed in the pool.
 4. the method of claim 1 whereinthe pool is heated by combustion.
 5. The method of claim 1 wherein thepool is heated by electric heating means.
 6. Apparatus for meltingglassy materials or the like comprising: a vessel mounted for rotationabout a substantially vertical axis, means to feed batch materials tothe vessel, means to heat the interior of the vessel, an outlet throughwhich partially melted material may flow from the vessel, a furnaceadapted to hold a pool of molten material drained from the vessel, andmeans to heat the pool of material held in the furnace.
 7. The apparatusof claim 6 wherein a plurality of the vessels are associated with thefurnace so as to pass partially melted material from each vessel to thefurnace.
 8. The apparatus of claim 6 wherein the furnace is providedwith combustion means.
 9. The apparatus of claim 6 wherein the furnaceis provided with heating electrodes in the pool.
 10. The apparatus ofclaim 6 wherein the vessel is metallic and is provided withsubstantially cylindrical side walls.